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Burnham IN10 manual except IN12 Gas Valves

Models: IN10

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(except IN12) Gas Valves

Figure 50: Operating Instruction, Intermittent Ignition System, VR8204 and VR8304

(except IN12) Gas Valves

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Burnham IN10 manual except IN12 Gas Valves

Contents

Installation Date INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FORINDEPENDENCE GAS - FIRED BOILERDANGER All cover plates, enclosures and guards must be in place at all times This boiler must be properly ventedFigure 1 Dimensional Drawing Appendix Table of ContentsVIII Figure 2 Section Tappings Table 1 Trim and Control Installation in Section TappingsDANGER I. Pre-InstallationFigure 3 Clearance to Combustible Materials A. Install Base-Burner-Manifold Assembly II. Knocked-Down Boiler AssemblyB. Install assembled cast iron sections on base assembly Figure 4 Base Gasket InstallationFigure 7 Canopy Gasket Installation D. Install CanopyFigure 8 Canopy Installation F. Install Jacket. See FigureFigure 12 Pilot and Gas Piping, Continuous Ignition Figure 10 Combustion ChamberStanding Pilot IN10 through IN12 Only Figure 13 Pilot and Gas Piping, Intermittent IgnitionFigure 15 Blocked Vent Switch Installation IN3 through IN9 I. Install Blocked Vent Switch with sheet metal screwsFigure 16 Blocked Vent Switch Installation IN10 through IN12 J. Intermittent Ignition EI Install Ignition ModuleD. Install Trim and Controls III. Semi-Pak Boiler AssemblyA. Remove Crate C. Identify Trim and ControlsFigure 19B Junction Box and Transformer Assembly Figure 19A Junction Box and Mounting Bracket Assembly4. Water Boiler Figure 20 Thermostat Isolation Relay AttachmentE. Install Jacket Front Panel IV. Packaged Boiler AssemblyB. Remove Jacket Front Panel. See Figure Figure 22 Securing Draft Hood to CanopyFigure 23 Trim Installation V. Piping and TrimFigure 24 Steam Boiler Piping Minimum Page Page Figure 28 Tankless Heater Piping Figure 27 Recommended Piping for Indirect Water HeaterPage Table 2 Rated Input VI. Gas PipingB. Connect boiler gas valve to gas supply system Figure 29 Recommended Gas PipingTable 4 Fitting Equivalent Lengths DANGERTable 5 Specific Gravity Correction Factors for Natural Gas less than 2000 ft. elevationDANGER VII. VentingC. Boiler Equipped With Vent Damper Do not use one vent damper to control two heating appliancesE. If an Existing Boiler is Removed Figure 30 Typical Vent InstallationNever jump out or make inoperative any safety or operating controls VIII. ElectricalB. Wire Vent Damper if used DANGERE. Alliance Indirect Water Heater if used Table 6 Thermostat Heat Anticipator SettingsFigure 33 Vent Damper Harness to Limit Figure 34 Vent Damper Schematic Wiring DiagramTHIS PAGE LEFT INTENTIONALLY BLANK Page 1. Normal Operation 2. Safety Shutdownc. Blocked Vent Switch. Automatically interrupts Page level. Normal operation resumes when water returns to normal level 2. Safety Shutdownc. Blocked Vent Switch. Automatically interrupts 1. Normal OperationPage 1. Normal Operation 2. Safety Shutdownc. Blocked Vent Switch. Automatically interrupts Page level. Normal operation resumes when water returns to normal level 2. Safety Shutdownc. Blocked Vent Switch. Automatically interrupts 1. Normal OperationPage 1. Normal Operation a. Thermostat calls for heat 2. Safety Shutdownb. Blocked Vent Switch. Automatically interrupts Page b. Blocked Vent Switch. Automatically interrupts 2. Safety Shutdown1. Normal Operation a. Thermostat calls for heat d. Sensor proves presence of pilot flame. MainPage 1. Normal Operation 2. Safety Shutdownb. Blocked Vent Switch. Automatically interrupts Page b. Blocked Vent Switch. Automatically interrupts 2. Safety Shutdown1. Normal Operation d. Sensor proves presence of pilot flame. MainPage 1. Normal Operation 2. Safety Shutdownb. Blocked Vent Switch. Automatically interrupts Page b. Blocked Vent Switch. Automatically interrupts 2. Safety Shutdown1. Normal Operation d. Sensor proves presence of pilot flame. MainC. Fill boiler with water IX. System Start-upD. Prepare to check operation Figure 46 Gas Valve Pressure Tap Honeywell Gas ValvesPage Page except IN12 Gas Valves Page Wiring Ladder Diagram Service ActionTable 7 Ignition Module Terminal Cross-Reference Figure 52 LED Locations TABLE 8 Yellow LED Flame CodesGreen LED Recommended Service ActionFlash Code IndicatesFigure 54 Pilot Burner Flame, Honeywell Q327 Figure 53 Pilot Burner Flame, Honeywell Q350Figure 55 Pilot Burner Flame, Honeywell Q348 Figure 56 40mm Main Burner Flame Figure 57 1 Main Burner FlameI. Check low water cutoff steam only K. Adjust gas input rate to boiler. Natural GasDo not drain below gauge glass J. Check LimitTable 10 Input Rate L. Adjust gas input rate to boiler. LP/Propane4. Add Boiler Water Treatment a. Remove safety valve Page B. Maintenance of Low Water Cutoff X. Service InstructionsDANGER DANGERE. Clean Boiler Flueways Figure 58 Boiler Flueway CleaningL. Tankless Heater Figure 59 Honeywell Q348 Spark GapTable 11 Pilot Burner Location M. Excessive Make-Up Water Honeywell Electronic Ignition Trouble Shooting Guide Honeywell Hot Surface to Pilot Trouble Shooting Guide Precautionary Measures Important Product Safety Information Refractory Ceramic Fiber ProductFirst Aid Procedures AVOID Breathing Fiber Particulates and DustSERVICE RECORD XI. Repair PartsSERVICE PERFORMED DATE1. Section Assembly 2. Canopy and Draft Hood Canopy/Draft Hood Parts Base Tray 3. Base AssemblyBase Wrapper Base End Insulation3. Base Assembly Continued Manifold and 1 Main Burners 3. Base Assembly ContinuedBurner Access Panel 4. Manifold and Main Burners 1 Inch Main Burners Only 4. Manifold and Main Burners 40MM MAIN BURNERS ONLY Manifold and 40mm Main BurnersIntermittent Ignition Only 24-Volt Continuous Ignition Standing Pilot Natural GasNatural Gas, High Altitude 2000-5000 Ft. USA Only 4. Manifold and Main Burners 40MM MAIN BURNERS ONLY ContinuedLP Gas, High Altitude 2000-5000 Ft. USA Only Natural Gas, High Altitude 5000-9000 Ft. USA Only5. Pilot Burner and Gas Valve, Continuous Ignition Standing Pilot, Natural Gas 5. Pilot Burner and Gas Valve, Intermittent Ignition EI, LP/Propane 5. Pilot Burner and Gas Valve, Intermittent Ignition EI, Natural GasPage Jacket Assembly Jacket Assembly Continued - Refer to Figure on Page Steam Trim Page Water Trim Quantity THIS PAGE LEFT BLANK INTENTIONALLY Page 14. Blocked Vent Switch 13. Flame Rollout Switch12. Transformer Steam and Gravity Water Only 15. Ignition Module Intermittent Ignition OnlyHow to Pipe XII. Low Water Cut Off LWCOHow to Wire How to TestONE YEAR LIMITED WARRANTY ON RESIDENTIAL GRADE WATER BOILERS Limited WarrantyLIFETIME LIMITED WARRANTY ON HEAT EXCHANGER PROCEDURE FOR OBTAINING WARRANTY SERVICEFIRST YEAR - LIMITED WARRANTY FOR RESIDENTIAL CAST IRON STEAM BOILERS Limited WarrantySECOND THROUGH 10 YEAR - LIMITED WARRANTY FOR THE CAST IRON SECTION ASSEMBLY OF RESIDENTIAL CAST IRON STEAM BOILERS